Method of forming simulated photographic prints

Abstract: Simulated photographic prints are created using xerographic imaging. A transparent substrate (25) having a xerographically formed mirror image fused thereto is bonded to a plastic substrate (116) through the use of heat and pressure. The transparent substrate (25) and the plastic substrate (116) form the finished print.

Description: This invention relates generally to a method for producing continuous tone images with near photographic print qualities using xerography. In the practice of conventional xerography, it is the general procedure to form electrostatic latent images on a xerographic surface by first uniformly charging a charge retentive surface such as a photoreceptor. The charged area is selectively dissipated in accordance with a pattern of activating radiation corresponding to original images. The selective dissipation of the charge leaves a latent charge pattern on the imaging surface corresponding to the areas not exposed by radiation. This charge pattern is made visible by developing it with toner by passing the photoreceptor past one or more developer housings. In monochromatic imaging, the toner generally comprises black thermoplastic powder particles which adhere to the charge pattern by electrostatic attraction. The developed image is then fixed to the imaging surface or is transferred to a receiving substrate such as plain paper to which it is fixed by suitable fusing techniques. Recently, there has been a great deal of effort directed to the development of color copiers/printers which utilize the xerographic process. Such efforts have resulted in the recent introduction of the Xerox™ 5775™ copier/printer and the Fuji Xerox A-Color 635 machine. The quality of color xerographic images on paper has approached the quality of color photographic prints. However, color xerographic prints fall short because they do not have the uniform gloss, dynamic range or brilliance typical of photographic prints. Nor do xerographic prints have the feel of photographic prints because the paper usually used is too lightweight and too limp. Typically the surface of color toner images is irregular, therefore, rather rough or lumpy. The behavior of incident white light vis-a-vis such color images is believed to be as follows: Some of the white light incident on the substrate carrying the color toner images specularly reflects off the substrate. Some of the light goes down into the paper, scatters around and comes back out in various directions, some through the toner and some not. Because the toner surface is rough or irregular some of the light incident thereon is reflected off the toner in various directions. Some of the light incident on the irregular toner surfaces passes through the toner into the paper and comes back out in various directions. White light becomes colored due to selective absorption as it passes through toner. The light then goes down into the paper and back out through the toner where it becomes more colored. As will be appreciated, any white light which does not pass through the toner diminishes the appearance of the final print. Attempts to make up this deficiency in conventionally formed color toner images have led to the lamination of xerographic images on paper using a transparent substrate. This procedure has been only partially successful because the lamination process tends to reduce the density range of the print resulting in a print that has less shadow detail. The lamination process also adds significant weight and thickness to the print. Additionally, it is believed that the aforementioned lamination process does not produce good results because typically the color toner images at the interface between the laminate and the toner do not make suitable optical contact. That is to say, the initially irregular toner image at the interface, is still irregular (i.e. contains voids) enough after lamination that light is reflected from at least some of those surfaces and is precluded from passing through the toner. In other words, when there are voids between the transparency and toner image, light gets scattered and reflected back without passing through the colored toner. Loss of image contrast results when any white light is scattered, either from the bottom surface of the transparent substrate or from the irregular toner surfaces and doesn't pass through the toner. A known method of improving the gloss of color xerographic images on a transparent substrate comprises refusing the color images. Such a process was observed at a NOMDA trade show in 1985 at a Panasonic exhibit. The process exhibited was carried out using an off-line transparency fuser, available from Panasonic as model FA-F100, in connection with a color xerographic copier which was utilized for creating multi-color toner images on a transparent substrate for the purpose of producing colored slides. Since the finished image from the color copier was not really suitable for projection, it was refused using the aforementioned off-line refuser. To implement the process, the transparency is placed in a holder intermediate which consists of a clear relatively thin sheet of plastic and a more sturdy support. The holder is used for transporting the imaged transparency through the off-line refuser. The thin clear sheet is laid on top of the toner layer on the transparency. After passing out of the refuser, the transparency is removed from the holder. This process resulted in an attractive high gloss image useful in image projectors. The refuser was also used during the exhibit for refusing color images on papers. However, the gloss is image-dependent. Thus, the gloss is high in areas of high toner density because the toner refuses in contact with the clear plastic sheet and becomes very smooth. In areas where there is little or no toner the gloss is only that of the substrate. JP-3050586 describes a method for obtaining a glossy image expressed with texture by using a transparent film as a transfer material and letting a white paper or a white plate closely contact with a transfer surface where a toner image is transferred after transferring the mirror image of an original. One object of the present invention is to create simulated color photographic prints wherein the print has the look and feel of a conventional black and white or color photograph. Accordingly, the present invention provides a method of forming simulated photographic prints, the method being in accordance with any one of the appended claims. Briefly, the present invention is carried out by first creating a multi-color, reverse reading (or mirror) toner image on a transparent substrate. The image created represents a wrong or reverse reading multi-color toner image when viewed from the toner side and is right reading when viewed through the transparent substrate. The multi-color toner image is xerographically created by sequentially forming different color toner images on the transparent substrate followed by the use of heat and pressure or other suitable means to affix or fuse the multi-color image to the transparent substrate such that there is good optical contact at the interface between the transparent substrate and the toner. The toner carrying side of the transparent substrate is then bonded to a light colored, substrate to provide a light color backing for effective reflection of light back through the toner image. The process may also be used for creating black and white simulated photographic prints. Satisfactory results have been obtained by placing the transparent substrate containing the toner images, image side up, on a tempered glass member and placing a sheet of light colored coated paper material in contact with the toner image carried by the transparent substrate. The side or surface of the sheet of coated paper material facing the toner image is provided with or serves as a carrier for a uniform coating of adhesive material for bonding the former to the latter. The tempered glass provides a smooth rigid support which rests on an elastomeric pad contained in a lower platen of a print making apparatus. An abhesive or non-stick member is placed on top of the plastic coated sheet material to provide for easy separation of the finished print from the print making apparatus. The non-stick member comprises a sheet of polyester material having one or both sides thereof coated with an abhesive material such as silicone rubber. A heated top platen is used to apply pressure and heat to the transparent substrate and the translucent sheet through the abhesive member to thereby effect bonding of the former to the latter. The resulting print exhibits an attractive and brilliant appearance which is more fade resistance and durable than commercially available photographic prints. Prints created in the foregoing manner have the look and feel of photographic prints but appear to have more brilliance. This is thought to be attributable to the xerographically formed prints having a lesser minimum density than conventional photographic prints resulting in whiter whites. A further advantage of this invention is that exceptionally good quality prints can be more quickly and more cost effectively produced than with conventional photographic printing techniques, especially in the case of larger size prints. Additionally, this process does not require silver, photographic chemicals, or intermediary negatives even when a black and white print is created from a color original. Still another advantage of the present invention is the capability of creating a high quality black and white print from a color original without the need to create an intermediary negative as is the case with existing photographic methods. This attribute enhances the potential uses of the process by making it far more cost effective than photographic processes would be in this case. Existing color xerographic copier/printer systems can be used for the process. Thus, all the resources associated with these products, particularly the ones which utilize state of the an electronic devices such as film scanners, image composition enhancers, color adjusters and editors can be utilized. The present invention will be described further, by way of example, with reference to the accompanying drawings, in which:- Figure 1 is a front elevational view of a device for making simulated photographic prints using the principles of xerography, Figure 2 is a schematic illustration of a device and materials for making a simulated photographic print using the principles of xerography and Figure 3 is a enlarged plan view of a simulated photographic print created according to an embodiment of the present invention. A print creation apparatus 91 (Figures 1-3) including upper and lower platen structures 92 and 94, respectively, is provided for producing simulated photographic prints using xerography. The lower platen comprises a rigid metal plate or base member 96 containing a silicone rubber pad 98 having a thickness of approximately 1.27cm (0.5 inch). A flat, rigid member supported on the silicone rubber pad comprises a 0.95cm (3/8 inch) thick, smooth-surfaced, tempered glass member 100. The smooth-surfaced tempered glass serves to smooth any wrinkles created in the transparency material during the imaging process. The upper platen 92 contains a heater structure (102) including heating elements 104 (Figure 2). The plate or base member 96 is provided with a leg structure 106 for supporting the the print making structure 91 on a suitable work surface such as a table. The upper platen 92 is hingedly secured via hinge structure 108 to an upper platen support structure 110. The support structure 110 is, in turn, operatively supported by a post member 112 received in a cylindrically shaped receiver member 114 forming an integral part of the plate or base member 96. The support structure is adapted to be pivoted relative to the base member 96 through the use of an arm and knob arrangement 115 attached to the support structure 110. The upper heated platen can thus be rotated either to the left or right (as viewed in figure 1) from its home position overlying the tempered glass member 100 in order to provide easy access thereto for inserting the materials used for print creation. In the process of forming a simulated photographic print according to the present invention, the transparency 25 containing the toner image 67 (Figures 2 an 3) is placed, image side up, on the tempered glass 100 and a light colored (i.e. white or near white) translucent sheet member 116 comprising a coated paper material is placed in contact with the toner image on the transparent substrate 25. The side or surface of the sheet of coated paper material facing the toner image is provided with or serves as a carrier for a uniform coating of adhesive material 118 which is applied to a thickness of about 0.000635cm (0.00025 inch). A number of adhesives can be selected for use in the present invention including materials that will enable the layers to substantially permanently bond to each other and not easily separate after extended time periods, such as for up to 1 year Specifically, a commercially available adhesive sold by the 3M Co. under the name of SUPER 77 has been used. The aforementioned adhesive is provided in a spray can dispenser and, therefore, it can be easily applied to the sheet 116. SUPER 77 spray adhesive is a high tack, high coverage material and a fast drying composition that has a heat activation temperature of about 107°C (225°F). Another suitable adhesive available from the 3M company and is designated as 556 Bonding Film. This bonding film comprises 40 to 50 % by weight of polyterpene resin, 30 to 40 % by weight of ethylene-vinyl acetate polymer, 10 to 20 % by weight of polyethylene and 1 to 10 % by weight of thermoplastic polymer. A layer of this bonding film may be applied directly to the sheets 116 or it may be transferred thereto using a carrier sheet containing the bonding film as provided by the manufacturer. In the case of the latter method, the sheet 116 and the film carrier are simultaneously heated while contacting each other for effecting transfer of the bonding film to the backing sheet 116. An abhesive or non-stick member 120 (Figure 2) is placed on top of the plastic coated sheet member 116. The member 120 comprises a sheet or film of polyester or Mylar, commercially available from E.I. DuPont which sheet has at least one of its sides coated with an abhesive layer 122 of silicone rubber. For sake of convenient use, both sides of the member 116 are provided with a layer 122. Thus, with both sides of the polyester film coated with silicone rubber, either side thereof can contact the sheet member 116. The film has a thickness of approximately 0.01 cm (0.004 inch) while each silicone layer has a thickness of approximately 5 to 10 microns. A suitable coated paper 116 is disclosed in U.S. Patent 5,075,153. As disclosed therein, the coated paper comprises a plastic supporting substrate such as polyester rather than natural cellulose, with certain coatings thereover Mylar, commercially available from E.I. DuPont is preferred as the substrate for the coated sheet 116 in view of its availability and lower cost. The coated sheet 116 has a thickness of about 0.01 cm (0.004 inch). The hinge mechanism 108 is located centrally of the upper platen 92 and serves to allow movement of the upper platen 92 relative to the support structure 110, such movement being toward the lower platen 94 for exerting pressure on the print forming members supported on the tempered glass member 100. Movement of the upper platen is effected through the use of a lever arm 126 adapted to be moved in in a direction out of the drawing sheet as viewed in Figure 1. Pressure variation or adjustment is effected through a pressure adjusting knob 128 and suitable linkage, not shown. The adjustment of the knob through its associated linkage mechanism serves to control the amount of pressure exerted between the upper and lower platens when the lever arm 126 is actuated. An electric cord, not shown, provides electrical current to the heating elements 104. The heating elements and thus the operating temperature of the print creation structure 91 is controlled via a temperature control 132 carried by the support structure 110 as shown in Figure 1. The operating temperature of the device is in the range of 105 to 120°C (220 to 250 °F). The pressure and heat are applied for between 15 to 20 seconds, the time being settable via a timer knob 134. During formation of a simulated photographic print, the transparent substrate and coated paper members are subjected to a total pressure in the order of 5 to 10 pounds over the area of 21.6x28 and 28x43cms (8.5x11 and 11x17 inch) print forming members. Since the translucent backing of the print is light colored, it exhibits a high degree of light reflectivity when a substantial portion of the incident light impinging thereon is directed toward the transparent surface. As will be appreciated since the final print comprises the translucent backing member and the transparent front member, the print may be illuminated from the rear with very pleasing results. The resulting simulated photographic print has a total thickness of approximately 0.0229cm (0.009 inch). Thus, a print 136 created according to the present invention has a thickness approximately equal to a conventional photograph which is approximately 0.0229cm (0.009 inch). The transparent substrate 25 without toner images thereon, coated paper 116, tempered glass 100 and abhesive or non-stick member 120 form a kit which can be used for creating simulated photographic prints. To this end, the transparent substrate 25 may be used in a machine like the 5775™ or any other suitable xerographic processor for forming either a black and white or color reverse reading image thereon. A commercially available heat and pressure device such as disclosed in Figure 1 can then be used to adhere a sheet of coated paper to the image side of the transparent substrate. A heat and pressure device contemplated for making simulated photographic prints using the aforementioned kit is currently used for applying decals (decal applicator) onto shirts and other articles of clothing. In carrying out the invention, once the image is formed on the transparent substrate and with the tempered glass member supported on the elastomeric base of the heat and pressure applying device, the transparent substrate and coated sheet are placed on top of the tempered glass. The abhesive member is placed on top of the coated sheet. Heat and pressure are then applied in a manner consistent with the normal operation of the decal applicator. While creation of simulated photographic prints has been disclosed in connection with one specific apparatus it will be appreciated that other apparatuses may be utilized for this purpose. For example, the transparent substrate and backing sheet may be bonded together using a pair of heat and pressure rolls forming a nip through which the substrate and sheet are passed.

Claims: A method of forming a simulated photographic print, said method including: contacting a wrong reading toner image (67) formed xerographically on one side of a transparent substrate (25) with a light color backing member (116); contacting said backing member (116) with an abhesive member (120); contacting a non-image side of said transparent substrate with a flat rigid surface (100); simultaneously applying heat and pressure at predetermined values to said substrate, backing member and abhesive member (120) whereby said substrate (25) and said backing member (116) adhere to each other to form said simulated photographic print; separating said abhesive member (120) from said backing member (116); and separating said simulated photographic print from said flat rigid surface (100). A method as claimed in claim 1, wherein said step of simultaneously applying heat and pressure comprises positioning said substrate (25), backing member (116), abhesive member (120) and flat rigid surface between a pair of platens (92, 94) at least one of which is provided with a source of heat energy capable of elevating the temperature of said substrate (25) and said backing member (116). A method as claimed in claim 2, wherein said step of simultaneously applying heat and pressure is effected by applying a force to one of said platens (92) in order to urge it in the direction of the other of said platens (94). A method as claimed in any one of claims 1 to 3, wherein said backing member (116) has a coating of adhesive material (118) on the side thereof which contacts the toner image (67). A method as claimed in any one of claims 1 to 4, wherein said backing member (116) is translucent. A method as claimed in any one of claims 1 to 5, wherein said abhesive member (120) comprises a polyester film having a silicone rubber coating on at least one side thereof. A method as claimed in claim 6, wherein said abhesive member (120) comprises a polyester film having a silicone rubber coating on each side thereof. A method as claimed in any one of claims 1 to 7, wherein the thicknesses of said simulated photographic print is approximately equal to 0.0229cm (0.009 inch). A method as claimed in any one of claims 1 to 8, wherein said flat rigid surface comprises tempered glass (100).

Inventors: CHERIAN ABRAHAM, CHERIAN, ABRAHAM
Applicants: XEROX CORP, XEROX CORPORATION
Application year: 1994
Main classification: G03G15
IPC codes: G03G13, G03G8, G03G15, G03B27